ROOT C.AUSE - CORRECTIVE ACTION:
Ever review an RCCA and find out it really doesn't go far enough, whereas you can continue to drill down into the issue to find the True Root Cause?
Ever actually answer the question in this method?
Q) What is True ROOT CAUSE?
A) True root cause is typically, the one cause you can't control, whereas you cannot control it.
So, if I can't control the true root cause, which is my "true" ROOT CAUSE"? It will be that one step just above the cause you cannot control.
Typically, that one cause that is just before the one you can't control is the one you can control. It should be worked down to the point that you can turn the defective on and turn the defective off just by introducing and then removing the "true" root cause.
Here's a little presentation of an example that you may find worthwhile.
Further, when working an RC/CA activity, look at the Human Factors issues that may be present. A great resource for Human Factors considerations can be found at TAP ROOT (r).
Check out their program and information. They offer an extremely important element to the Root Cause Corrective Action process, if not one of the best methoddologies to identify true root cause.
In Aviation manufacturing, the push is for Process Control and Variation Management, does your Corrective Action process point your personnel to perhaps look back at the PPAP, PFMEA, DFMEA, MSA processes and your control plans and AS9103 Key Characteristics and Variation Management?
Is your company one that says, "Oh, if the Key Characteristic isn't on the drawing, we don't have to do AS9103 Variation Managment."?
Have you looked at the support tools from the IAQG SUPPLY CHAIN MANAGEMENT HANDBOOK? They have some remarkable tools available for participants, and they're all FREE. You just need to register at their web site.
It's AQP's feeling that just about every defective, be it process or product related has a variable in it that is not controlled, ergo, place a driver or pointer in your corrective action processes to ensure the personnel working the process have a pointer to consider and/or even require them to look at the "Control" of that process and what changes may be needed to bring the process under control to ensure the defective is removed.
If it's a human factors issue, which when you look historically at your corrective actions and defectives, we will bet that most everyone will point to a human factor issue, i.e., someone was supposed to do something and didn't - which, in our experience isn't because they didn't want to, it's simply because they didn't know and what's the net result? A work instruction improvement or modificatioin, a new instruction or procedure/methodology, or the beginning of a program, such as Preventive Maintenance, Small Tool Control programs, Small Parts Hardware Control programs, etc.
For assistance in developing robust RCCA activities for your organization, contact us and we'll talk thru your needs and see what solutions we can provide for you. If not us, we may have the contact information of the expert that can help you in your initiatives.